Mold and mold basket for use in uni-directional solidification process in a liquid metal bath furnace

Abstract

A mold basket, for supporting a mold, for use in a liquid metal bath furnace with an elevator, comprising a flange for suspending the mold basket from the elevator; and a horizontal plate disposed beneath the flange for supporting the mold, wherein the plate is coupled to the flange with a plurality of vertical tie rods.

We claim:  
     
       1. A unidirectional mold basket for supporting at least one unidirectional mold for insertion in a liquid metal bath furnace, said mold basket comprising: 
       a flange for suspending said mold basket, said flange having at least one aperture for receiving said at least one unidirectional mold, wherein said aperture is defined by an inner wall of said flange, said inner wall being radially disposed in spaced apart relation to said unidirectional mold and acting as a detent to limit lateral movement of said unidirectional mold, and wherein said unidirectional mold is slidably removable vertically relative to said inner wall;  
       a horizontal plate disposed beneath said flange for supporting said unidirectional mold, said horizontal plate being thermally conductive; and  
       a plurality of tie rods, each of said tie rods having a first rod end received in a rod aperture in said horizontal plate and a second rod end received in a corresponding rod aperture in said flange, said second rod end being distal from said first rod end, wherein said plurality of tie rods extend vertically between said horizontal plate and said flange, thereby connecting said horizontal plate to said flange.  
     
     
       2. The unidirectional mold basket of  claim 1  wherein said aperture provides lateral support for said mold and allows slidable vertical movement of said mold relative to said mold basket. 
     
     
       3. A unidirectional mold basket for supporting a unidirectional mold for use in a liquid metal bath furnace, said mold basket comprising: 
       a basket flange for suspending said mold basket, said basket flange having at least one aperture for receiving said at least one unidirectional mold, wherein said aperture is defined by an inner wall of said basket flange, said inner wall inner wall being radially disposed in spaced apart relation to said unidirectional mold and acting as a detent to limit lateral movement of said unidirectional mold, and wherein said unidirectional mold is slidably removable vertically relative to said inner wall;  
       a horizontal plate disposed beneath said flange for supporting said unidirectional mold, said horizontal plate being thermally conductive; and  
       a plurality of tie rods for connecting said basket flange to said horizontal plate, each of said tie rods having a first end and a second end distal from said first end, wherein said first end is received in a corresponding rod aperture in said basket flange and said second end is received in a corresponding rod aperture in said horizontal plate.  
     
     
       4. The unidirectional mold basket of  claim 3  wherein said rod apertures are guide slots. 
     
     
       5. The unidirectional mold basket of  claim 4  wherein each of said first and second ends of said tie rods are comprised of first and second rod flanges respectively, wherein said first rod flange engages a top surface of said basket flange and said second rod flange engages a bottom surface of said plate for effecting suspension of said plate from said basket flange. 
     
     
       6. The unidirectional mold basket of  claim 1 , wherein said flange, said tie rods, and said horizontal plate are formed from refractory materials that are resistant to corrosion by liquid aluminum. 
     
     
       7. The unidirectional mold basket of  claim 1 , wherein said flange, said tie rods, and said horizontal plate are formed from refractory materials selected from the group consisting of alumina, nextel, silicon carbide, graphite/silicon carbide composite, silicon carbide/silicon carbide composite, and carbon/carbon composite. 
     
     
       8. The unidirectional mold basket of  claim 3 , wherein said flange, said tie rods, and said horizontal plate are formed from refractory materials that are resistant to corrosion by liquid aluminum. 
     
     
       9. The unidirectional mold basket of  claim 3 , wherein said flange, said tie rods, and said horizontal plate are formed from refractory materials selected from the group consisting of alumina, nextel, silicon carbide, graphite/silicon carbide composite, silicon carbide/silicon carbide composite, and carbon/carbon composite. 
     
     
       10. A unidirectional mold basket for supporting at least one unidirectional mold for use in a liquid metal bath furnace with an elevator, said mold basket comprising: 
       a flange for suspending said mold basket from said elevator, said flange having at least one aperture for receiving said at least one unidirectional mold, wherein said aperture is defined by an inner wall of said flange, said inner wall being radially disposed in spaced apart relation to said unidirectional mold and acting as a detent to limit lateral movement of said unidirectional mold, and wherein said unidirectional mold is slidably removable vertically relative to said inner wall;  
       a horizontal plate disposed beneath said flange for supporting said unidirectional mold, said horizontal plate being thermally conductive; and  
       a plurality of tie rods, each of said tie rods having a first rod end received in a rod aperture in said horizontal plate and a second rod end received in a corresponding rod aperture in said flange, said second rod end being distal from said first rod end, wherein said plurality of tie rods extend vertically between said horizontal plate and said flange, thereby connecting said horizontal plate to said flange.  
     
     
       11. The unidirectional mold basket of  claim 10 , wherein said aperture provides lateral support for said mold and allows slidable vertical movement of said mold relative to said mold basket. 
     
     
       12. The unidirectional mold basket of  claim 10 , wherein said rod apertures are guide slots. 
     
     
       13. The unidirectional mold basket of  claim 12 , wherein each of said first rod end and second rod end of each of said plurality of tie rods are comprised of a first rod flange and second rod flange, respectively, wherein said first rod flange engages a top surface of said flange and said second rod flange engages a bottom surface of said horizontal plate for effecting suspension of said horizontal plate from said flange. 
     
     
       14. The unidirectional mold basket of  claim 10 , wherein said flange, said tie rods, and said horizontal plate are formed from refractory materials that are resistant to corrosion by liquid aluminum. 
     
     
       15. The unidirectional mold basket of  claim 10 , wherein said flange, said tie rods, and said horizontal plate are formed from refractory materials selected from the group consisting of alumina, nextel, silicon carbide, graphite/silicon carbide composite, silicon carbide/silicon carbide composite, and carbon/carbon composite.